Tape lamination machine scrap collection assembly

ABSTRACT

A scrap collection assembly for a tape lamination head that applies a plurality of composite tape segments includes a crack-off assembly with a scrap crack-off redirect roller configured to engage one or more composite tape segments and one or more scrap portions; a secondary crack-off roller configured to engage one or more composite tape segments and one or more scrap portions; a pivot that connects the crack-off assembly to the tape lamination head, wherein the secondary crack-off roller selectively moves about the pivot to change a direction of composite tape movement; and a conveyor that receives the scrap portion(s) from the secondary crack-off roller.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This is a U.S. Non-provisional patent application claiming the benefitof priority from U.S. Provisional patent application No. 62/971,032filed on Feb. 6, 2020, the entire contents of which are incorporatedherein.

TECHNICAL FIELD

The present application relates to tape lamination machines and, moreparticularly, to a scrap collection assembly included with a tapelamination head.

BACKGROUND

Tape lamination machines are used to create composite workpieces.Composite material, in the form of fibrous material impregnated withresin, is applied by the machines at precise locations and lengths tocollectively form a composite workpiece. The tape lamination machinemoves a tape lamination head to precisely apply composite tape in theultimate shape of the composite workpiece. As the tape lamination headmoves, it leaves a plurality of composite tape segments, also referredto as a course behind. The automatic application of these composite tapesegments involves the cooperation of a diverse collection of machinerythat holds, moves, and ultimately cuts the composite tape.

Each composite tape segment can include a head portion and a tailportion at ends of the segment. The head portion and the tail portionare shaped by a cutting blade that cuts the composite tape therebyforming the tail portion of one composite tape segment and the headportion of a subsequent composite tape segment. Some composite tapesegments have relatively simple shapes, such as a butt cut, thatsimultaneously separates the tail portion of one composite tape segmentfrom the head portion of another composite tape portion. However, othercomposite tape segments may be created from cuts in the suppliedcomposite tape that leaves unwanted scrap material on backing paper thatwill be disposed.

SUMMARY

In one implementation, a scrap collection assembly for a tape laminationhead that applies a plurality of composite tape segments includes acrack-off assembly with a scrap crack-off redirect roller configured toengage one or more composite tape segments and one or more scrapportions; a secondary crack-off roller configured to engage one or morecomposite tape segments and one or more scrap portions; a pivot thatconnects the crack-off assembly to the tape lamination head, wherein thesecondary crack-off roller selectively moves about the pivot to change adirection of composite tape movement; and a conveyor that receives thescrap portion(s) from the secondary crack-off roller.

In another implementation, a tape lamination head for applying aplurality of composite tape segments, include a frame that carries asupply reel of composite tape and a plurality of redirect rollers; acrack-off assembly comprising: a scrap crack-off redirect rollerconfigured to engage one or more composite tape segments and one or morescrap portions; a secondary crack-off roller configured to engage one ormore composite tape segments and one or more scrap portions; a pivotthat connects the crack-off assembly to the tape lamination head,wherein the secondary crack-off roller selectively moves about the pivotto change a direction of composite tape movement; and a conveyor thatreceives the scrap portion(s) from the secondary crack-off roller.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view depicting an implementation of a tapelamination machine;

FIG. 2 is a perspective view depicting an implementation of a tapelamination head; and

FIG. 3 is another perspective view depicting an implementation of aportion of a tape lamination head;

FIG. 4 is a plan view depicting an implementation of a pattern ofapplied composite tape sections and a composite tape section along withscrap on backing paper;

FIG. 5(a) is a perspective view depicting an implementation of a portionof a scrap collection assembly in a tape laying mode or position;

FIG. 5(b) is a perspective view depicting an implementation of a portionof a scrap collection assembly in a scrap collecting mode or position;

FIG. 6 is a profile view depicting an implementation of a portion of ascrap collection assembly; and

FIG. 7 is a profile view depicting another implementation of a tapelamination head.

DETAILED DESCRIPTION

A tape lamination machine includes a tape lamination head having a scrapcollection assembly for removing scrap composite tape from backing paperand storing the scrap sections at the head. As discussed above, thecreation of composite tape segments sometimes involves the creation ofscrap segments of composite tape that is ultimately discarded. Forexample, the tail of a composite tape segment can be cut at a differentangle than the head of a subsequent composite tape segment. A scrapportion of composite tape can be formed between or within sequential orcomposite tape segments cut in this way. In the past, the tapelamination head may have been moved away from a table base to a scrapremoval location where the scrap section was removed from the backingpaper by a machine operator. But this slows the rate at which compositetape segments can be applied thereby slowing the formation of acomposite part. In contrast, the tape lamination head can collect scrapportions in situ with a scrap collection assembly the head carries. Ascomposite tape passes through the tape lamination head and a cuttingassembly cuts the tape to create one or more scrap portions, the scrapcollection assembly can be activated to remove the scrap portion(s) fromthe backing paper and collect it in a collection tray. The scrapcollection assembly can include a crack-off assembly, a conveyor, and acollection tray that will be discussed in more detail below.

After the cutting assembly cuts composite tape moving through the tapelamination head and creates a scrap portion, the scrap portionultimately reaches a scrap position and a secondary crack-off roller canmove into engagement with the backing paper affixed to the compositetape moving toward a compaction assembly. The engaged secondary rollercan create a back bend in the composite tape path and direct the scrapportion toward the conveyor that draws the scrap portion away from thebacking paper and communicates the scrap section into the collectiontray. The scrap collection assembly can remove the scrap sectionswithout assistance of an operator and without moving the tape laminationhead to a scrap removal location.

An implementation of a tape lamination machine 10 is shown in FIG. 1.The tape lamination machine 10 includes a gantry 12 that movably carriesa tape lamination head 14 over a table base 16 on which composite partsare formed from a plurality of composite tape segments. The gantry 12can include vertical supports 18 that are linked via a horizontalsupport 20 or beam attached at an upper end of the vertical supports 18.The gantry 12 can be implemented as a multiple-axis tape laminationmachine 10, such as a Cincinnati CHARGER ATL or GEMINI. In oneimplementation, the tape lamination machine 10 can permit six-axismovement of the tape lamination head 14. The bottom of the verticalsupports 18 can move linearly along an X-axis relative to the table base16. The bottom of the vertical supports 18 can move over rails 22 orwheels to move the gantry 12 along the X-axis. In one embodiment, therails 22 can be included on the table base 16 such that the verticalsupports 18 rest on the table. In other implementations, rails 22 can beformed on the floor where the tape lamination machine 10 is installed. Aram 24 can carry the tape lamination head 14 to raise and lower the head14 relative to the table base 16 along the Z-axis. The tape laminationhead 14 can be slidably connected to the horizontal support 20 at an endof the ram 24 distal to the tape lamination head. The slidable connectorcan permit the frame to move in the Y-axis direction over the table base16. A releasable connector 26 between the tape lamination head 14 andthe ram 24 can permit the removal and replacement of a tape laminationhead. The vertical supports 18 and ram 24 can move along the X-, Y-, andZ-axes to position the tape lamination head 14 with respect to areplacement station 28. Afterwards, another tape lamination head 14 canbe coupled to the ram 24 and moved by the gantry 12 into position overthe table base 16.

Movement of the gantry 12, including the vertical supports 18 and theram 24 can be controlled by an operator station 30. The operator station30 includes one or more microprocessors (not shown) in communicationwith a computer readable storage medium having executable instructionscan control movement of fluidic rams, electric motors, or other driveelement thereby controlling the motion and position of the gantry 12 aswell as the operation of the tape lamination head 14. Themicroprocessor(s) can be any type of device capable of processingelectronic instructions including microcontrollers, host processors,controllers, and application specific integrated circuits (ASICs). Itcan be a dedicated processor used only to carry out control of thegantry 12 or can be shared with other machine functions. Themicroprocessor executes various types of digitally-stored instructions,such as software or firmware programs stored in memory. Communicationsbetween the mechanisms that move the gantry 12 and the tape laminationhead 14, such as the fluidic rams or electric motors, and themicroprocessor(s) can be carried out over a communications bus.

Turning to FIGS. 2 and 3, the tape lamination head 14 includes a frame32 coupled to a releasable connector 26 that releasably attaches thehead to the ram 24. The frame 32 can support a supply reel 34 carryingcomposite tape 36 that is ultimately supplied to a compaction assembly38 applying the tape 36 to the table base 16. Along the way, thecomposite tape 36 can pass over a supply dancer 40, a first redirectroller 42, a second redirect roller 44, and a scrap crack-off redirectroller 46 that collectively route the tape 36 adjacent to a cuttingassembly 48. Composite tape 36 can be wound around the supply reel 34 inone of a variety of widths. For example, composite tape 36 having awidth of 1.5″ to 12″ can be wound around the supply reel 34 for laterunwinding as the composite tape 36 is passed through the tape laminationhead 14. The composition of composite tape 36 is known and can includecarbon fiber as an example of composite tape. A backing paper 50 can beapplied to one side of the composite tape 36 so that a surface of thecomposite tape 36 does not touch subsequently wound layers of tape 36.The supply dancer 40, the first redirect roller 42, and the secondredirect roller 44 can be attached to dancer mechanisms 52 that controlthe tension exerted on the composite tape 36 pulled from the supply reel34 and communicated to the compaction assembly 38. The dancingmechanisms 52 can permit linear movement of the rollers under control ofa spring or a hydraulic ram. One or more electric motors can be used toapply rotational force to the supply reel 34, the supply dancer 40, thefirst redirect roller 42, or the second redirect roller 44. A backingpaper reel 54 is included with the tape lamination head 14 and canaccept backing paper 50 that has been removed from the composite tape 36before the tape 36 is applied to the table base 16. In oneimplementation, servo motors are used that are powered by servo drivesto control movement of the composite tape 36 along the supply reel 34,the supply dancer 40, or the backing paper reel 54.

The compaction assembly 38 applies composite tape section to the tablebase 16. The compaction assembly 38 can include a compaction roller 84that presses the composite tape segment onto the table base 16 as wellas a tail separation assembly. In some implementations, the compactionassembly 38 include a compaction slide.

The cutting assembly 48 is included with the tape lamination head 14 andmoves along a linear path in a direction of composite tape movement viaa cutter carriage 56. The linear path can be a rail 58 or slot overwhich the cutting assembly 48 moves linearly, adjacent to the path ofcomposite tape moving toward the compaction assembly 38. In thisimplementation, the cutting assembly 48 moves vertically from a topportion 60 of the tape lamination head 14 to a bottom portion 62 of thehead 14. A linear motor 64 can move the cutting assembly 48 along therail 58 in the same direction or plane in which the composite tape 36moves toward the compaction assembly 38. As the cutting assembly 48approaches an end of its movement, a crash stop 66 can help stop thedownward movement of the assembly 48.

The cutting assembly 48 can include a cutting blade 68 that cutssections of composite tape 36 against a cutting anvil 70 as the tape 36travels toward the compaction assembly 38. Rather than stopping themovement of composite tape 36 through the tape lamination head 14, thecutting assembly 48 can be moved in coordination with the tape 36 sothat the cutting blade 68 is traveling at the same velocity as the tape36. In that way, the only relative motion between the composite tape 36and the cutting blade 68 occurs when the blade 68 is moved to cut thetape 36.

The composite tape 36 can be cut into a variety of shapes as is shown inFIG. 4. The section of composite tape is shown with a composite tapesegment 86 that will be applied to the table base 16 and scrap portions88. The composite tape segments 86 are shown included with the scrapportions 88 after cutting but before removal of both from the backingpaper 50. A pattern showing the composite tape segments 86 applied tothe table base 16 is shown as well. After cutting the composite tape 36into a composite tape segment 86 and a scrap portion 88, the compositetape 36, including both the composite tape segment 86 and the scrapportion 88 attached to the backing paper 50, moves toward a scrapcollection assembly 90.

The scrap collection assembly 90, shown in FIGS. 5(a) and 5(b), caninclude a crack-off assembly 92, a conveyor 94, and a collection tray 96that collectively work together to remove the scrap portion 88 from thebacking paper 50 before passing the composite tape segment 86 to thecompaction assembly 38 that applies the composite tape segment 86 to thetable base 16. The composite tape segment 86 and scrap portion 88 followa tape path that includes a second redirect roller 44 and a scrapcrack-off redirect roller 46. The second redirect roller 46 can be apassive roller fixedly mounted on the frame and serving to change thedirection of the tape path as the composite tape travels toward thecompaction assembly. The scrap crack-off redirect roller 46 can alsopassively change the direction of the tape path as the composite tape 36travels toward the compaction assembly 38. However, the scrap crack-offredirect roller 44 can be included with the crack-off assembly 38 alongwith a secondary crack-off roller 98 that can selectively change thedirection of composite tape travel or the shape of the tape path whilepositioned in a scrap collecting mode. The crack-off assembly 92includes the scrap crack-off redirect roller 46, the secondary crack-offroller 98, a pivot 100, and a piston 102 or similar mechanical orelectromechanical actuator that selectively moves the crack-off assembly92 between a tape laying mode and a scrap collecting mode. In someimplementations, the scrap crack-off redirect roller 46 can rotate orspin about an axis of pivot rotation for pivot 100. The crack-offassembly 92 can comprise a roller frame 104 that carries the scrapcrack-off redirect roller 46 and the secondary crack-off roller 98. Thepivot 100 can rotatably link the crack-off assembly 92 to the frame 32of the tape lamination head 14. The piston 102, such as a fluidic ram ora linear motor, can extend or retract thereby moving the crack-offassembly 92 about the pivot 100. In other implementations, a differentmechanical actuator could be used. The secondary crack-off roller 98 ispositioned opposite the scrap crack-off redirect roller 46 such that thesecondary crack-off roller 98 can contact the backing paper 50 and thescrap crack-off redirect roller 46 can contact the composite tape 36.

In a tape laying mode, the crack-off assembly 92 can be positioned sothat the tape path is influenced by the second redirect roller 44 andthe scrap crack-off redirect roller 46 as the composite tape 36 passesto the compaction assembly 38. The position of the crack-off assembly 92in tape laying mode or position is shown in FIG. 5a . When a compositetape segment 86 is cut and a scrap portion 88 is created as part of thecut, the crack-off assembly 92 can be moved into a scrap-collection modeor position where the crack-off assembly 92 changes the tape path ordirection of composite tape 36 toward the conveyor 94 that transfers thescrap portion 88 to the collection tray 96. The position of thecrack-off assembly 92 in scrap-collection mode is shown in FIG. 5b . Inthis embodiment, the crack-off assembly 92 rotates about the pivot 100so that the secondary crack-off roller 98 engages the backing paper 50of the composite tape 36 and changes the tape path or direction so thatthe scrap portion 88 can be received by the conveyor 94. Once the scrapportion 88 is received by the conveyor 94 the crack-off assembly 92moves back to the tape laying mode position and the composite tapesegment 86 can travel to the compaction assembly 38.

A conveyor 94 can receive scrap portions 88 and transfer them to thecollection tray 96. The conveyor 94 can include two opposed belts 106,108 that counter rotate to pull the scrap portion 88 from the backingpaper 50 and transfer it to the collection tray 96. One end of the belts106, 108 is positioned adjacent to the second redirect roller 44 suchthat scrap portions 88 pass in between the second redirect roller 44 andthe scrap crack-off redirect roller 46. A first belt 106 can rotate in acounter-clockwise direction and a second belt 108 can rotate in aclockwise direction while the first belt 106 and the second belt 108engage each other. The collective motion of the first belt 106 and thesecond belt 108 can move scrap portions 88 from the second redirectroller 44 along a scrap path 110 to another end of the belts 106, 108where the collection tray 96 receives the scrap portion 88. The firstbelt 106 and second belt 108 can be made of a rubberlike material thatis flexible but also has a sufficient coefficient of friction that pullsthe scrap portion 88 off the backing paper 50 and holds the scrapportion 88 between the belts 106, 108 as the portion is transferred tothe collection tray 96. The collection tray 96 can be a container thatis sized to accept a particular length and quantity of scrap portions88. The collection tray 96 can also be removable from the tapelamination head 14 so that scrap portions 88 can be disposed of. Inanother implementation, the collection tray 96 can be replaced with ascrap spool 112 that receives scrap portions 88 from the conveyor 94 andwinds the portions around the scrap spool 112 as is shown in FIG. 7. Thescrap spool 112 can be configured to handle longer lengths of scrapportions 88 as they exit the conveyor 94. The scrap portions 88 can rollup on the scrap spool 112 on a scrap roll up medium such as shippingtape.

It is to be understood that the foregoing is a description of one ormore embodiments of the invention. The invention is not limited to theparticular embodiment(s) disclosed herein, but rather is defined solelyby the claims below. Furthermore, the statements contained in theforegoing description relate to particular embodiments and are not to beconstrued as limitations on the scope of the invention or on thedefinition of terms used in the claims, except where a term or phrase isexpressly defined above. Various other embodiments and various changesand modifications to the disclosed embodiment(s) will become apparent tothose skilled in the art. All such other embodiments, changes, andmodifications are intended to come within the scope of the appendedclaims.

As used in this specification and claims, the terms “e.g.,” “forexample,” “for instance,” “such as,” and “like,” and the verbs“comprising,” “having,” “including,” and their other verb forms, whenused in conjunction with a listing of one or more components or otheritems, are each to be construed as open-ended, meaning that the listingis not to be considered as excluding other, additional components oritems. Other terms are to be construed using their broadest reasonablemeaning unless they are used in a context that requires a differentinterpretation.

What is claimed is:
 1. A tape lamination head for applying a pluralityof composite tape segments, comprising: a frame that carries a supplyreel of composite tape and a plurality of redirect rollers; a crack-offassembly comprising: a scrap crack-off redirect roller configured toengage one or more composite tape segments and one or more scrapportions; a secondary crack-off roller configured to engage one or morecomposite tape segments and one or more scrap portions; a pivot thatconnects the crack-off assembly to the tape lamination head, wherein thesecondary crack-off roller selectively moves about the pivot to change adirection of composite tape movement; and a conveyor that receives theone or more scrap portions from the secondary crack-off roller.
 2. Thetape lamination head recited in claim 1, further comprising a collectiontray that is configured to receive the one or more scrap portions fromthe conveyor.
 3. The tape lamination head recited in claim 2, whereinthe collection tray is configured to be removable from a scrapcollection assembly.
 4. The tape lamination head recited in claim 1,further comprising a scrap spool that receives the one or more scrapportions from the conveyor.
 5. The tape lamination head recited in claim1, further comprising a piston attached to the frame of the tapelamination head and a scrap collection assembly that rotates thecrack-off assembly about the pivot.
 6. The tape lamination head recitedin claim 1, wherein the scrap crack-off redirect roller rotates about anaxis of pivot rotation of the pivot.